2015 KEPIC PERFORMANCE TEST SEMINAR New Start! Open Soft Speed AGAIN KEPCO! 2015. 9. 22 KEPCO KEPRI Kim eui hwan
1 2 3 test Steam turbine test 2/42
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Thermal analysis of Power Plant Cycle Grasp of the performance on,, Plant & Aux. Thermal performance analysis & evaluation 4/42 Operation condition optimization, Selection of max. efficiency Improvement & Deduction of performance degradation Verification of guaranteed performance for new units Suggestion of the evaluation information for electric deal Consideration of countermeasure on thermal loss cause Derivation of bench mark data for future use Suggestion of the economic grid information
Sorts by test goals Acceptance / periodic / cost evaluation / special goal performance test, etc. Sorts by test scale Full scale / semi-full scale / simplified or informality test, etc. Sorts by test equipments section / / Plant / Auxiliaries test, etc. 5/42
Sorts Implement time Test equipments Test load Test number P e r i o d i c T e s t Thermal power Plant Combined Cycle Power Plant A-classoverhaul B-classoverhaul A-classoverhaul B-classoverhaul Befor : Within 5 months Befor : Within 3 months Befor : Within 5 months Befor : Within 3 months After : Within 3 months After : Within 3 months After : Within 2 months After : Within 2 months Main boiler, Air heater Main turbine, Condenser, Feed water heater Before: 100% After : 100, 75% 100% 2 75% 1 Before : 100% After : 100% 2 Combined cycle (GT, HRSG, ST & Auxiliary) Before: 100% After : 100, 75% 100% 2, 75% 1 Test time Minimum 2 hours Minimum 1 hours Before : 100% After : 100% Steady load time Minimum 1 hours (If possible 2 hours) The same left Test supervision Local place(operation division ) The same left Test participation Test specialized agency Local place Test specialized agency Local place Test witness - - Test result calculation Test specialized agency Local place Test specialized agency Local place Use instrument Test specialized agency 6/42 Local place Test specialized agency 2 Local place
Sorts Thermal Power Acceptance test Combined Power Cost evaluation test Thermal Power Combined Power A-class overhaul A-class overhaul Implement time Within 3 months after Reliability test Within 3 months after overhaul Test equipments Main body etc, Contract guarantee item of thermal performance Net (Gross) Plant thermal efficiency & auxiliary power consumption Test load Nominal rating test load by guarantee item of thermal performance MAR 100%, 80%, 60% & Minimum stable load Test number Each Load 2 times Each Load 2 times Test time Minimum 2 hours Coal 4 hours Minimum 1 hours Minimum 2 hours Minimum 1 hours Steady load time The same above The same above Test supervision The same above The same above Test participation Test specialized agency Test service consignment agency Test witness Contractor( supply company of main plant ) Korea power exchange Test result calculation Test specialized agency (& Contractor) Test service consignment agency Use instrument Agreement by contract Test service consignment agency 7/42
Since 1984 Year 2013.12.31 Division Kind Fossil CC Internal Hydro Nuclear Total AT 90 112 69 26 4 301 Power company PT 384 83 24 15 25 531 CET 168 85 13 - - 266 Total 642 280 106 41 29 1,098 AT 3 4 - - - 7 Private company Oversea Power Plant PT 4 12 - - - 16 CET 13 67 - - - 80 Total 20 83 - - - 103 AT 6 8 - - - 14 PT 20 13 - - - 33 CET - - - - - Total 26 21 - - - 47 AT 99 124 69 26 4 322 PT 408 108 24 15 25 580 CET 181 152 13 - - 346 Total 688 384 106 41 29 1,248 AT : Acceptance Test, PT: Periodic Test, CET: Cost Evaluation Test 8/42
ASME PTC Equipment Codes (36 PTCs) General Documents in Support of Equipment Codes (15 PTCs) PTC : Performance Test Code 9/42
EQUIPMENT CODES POWER PRODUCING COMBUSTION & HEAT TRANSFER FLUID HANDLING ALLIED POLLUTION CONTROL 6 : Steam s 4 : Fired S/Gs 7.1 : Rotary Pumps 4.2 : Coal Pulverizers 21 : Particle Matter 18 : Hydraulic TBNs 4.3 : Air Heaters 7.2 : Power Pumps 25 : Press. Relief Device Collection Equipment 18.1 : Pumping Mode of 4.4 : HRSG 8.2 : Centrifugal Pumps 39 : Steam Traps 40 : Flue Gas Pump/s 12.1 : Closed FW 9 : Displacement PM : Performance Desulfurization 22 : Gas s Heaters Compressors, Monitoring 45 : Emission Testing of 42 : Wind s 12.2 : STM Surface Vac. Pumps, Guidelines Municipal Waste 46 : Overall Plant Condensers & Blowers for Steam Combustors Performance 12.4 : MSR 10 : Compressors, Power Plants 47 : IGCC 30 : Air Cooled & Exhausters 50 : Fuel Cells Heat Exchangers 11 : Fans 32.1 : NSSS 12.3 : Deaerators 10/42
GENERAL DOCUMENTS IN SUPPORT OF EQUIPMENT CODES MEASUREMENT OF ASSOCIATED PHENOMENA MEASUREMENT OF PROCESS PARAMETERS AND TEST UNCERTAINTY GENERAL INFORMATION 3.1 : Diesel & Burner 19.1 : Measurement Uncertainty Fuels 19.2 : Press. Measurement 3.2 : Coal & Coke 3.3 : Gaseous Fuels 19.3 : Temperature Measurement 19.10 : Flue & Exhaust 19.5 : Flow Measurement Gas Analysis 28 : Properties of Fine 19.11 : STM&WTR Purity in the Power Cycle Particulate Matter 19.22 : Digital Systems Techniques 36 : Measurement of Industrial Sound 19.25 : Transient Measurement Uncertainty 11/42 1 : General Instruction 2 : Definitions & Values
Test procedure Test preparation Preliminary test Main test test procedure writing & review Test procedure discussion & decision Test fuel securement Instruments selection, calibration, installation, check in state of working Clear of problem after preliminary test Operation condition : operation mode, maintain of design value, system isolation Steady load operation : within acceptable deviation limit on average value / instantaneous value Test data acquisition, availability evaluation, arrangement Test results Test result calculation Test result Reporting 12/42
Review of test calculation program sheet Fuel securement for test (Fuel characteristic, quality, design approach) Test instruments select, Calibration, Installation, check in working state Plant maintenance, especially steam, feed water, gas leak, etc. Power securement of test load Reference preparation supplied contract, test procedure, schedule plan, correction curve, etc. Selection & education for test recording persons 13/42
Maintenance of test fuel quality Maintenance of coal plant test load & mixed ratio before 3 hours Soot Blowing & Bottom Ash handling before test Full up make-up water Tank, FO Daily Tank, Coal Bunker before test and no make-up during the test Flue Gas analysis and O2 content maintenance before test Maintenance of Steady thermal state for more than 2 hours Load Limiter operation 14/42
Outside leak flow control for minimization test error of test result Measurement in case of enable to flow control Unaccountable flow limitation - Steam turbine inlet flow 0.1 % below (only Combined steam turbine 0.25 %) - Simplified thermal performance test : 0.3 % below Testing after detailed checking of over leakage 15/42
Item Max - Min Average contrast Main steam Pr. above 34 kg/ cm2 1.70 kg/ cm2 ± 1.36 kg/ cm2 Main steam Temp 11.11 ± 5.56 BLR Feed Water Temp 11.11 ± 5.56 Main steam flow 4 % ± 3 % feed water flow Drum Type 10 % ± 3 % O 2 Content Oil & Gas power Plant 0.4 %P ± 0.2 %P O 2 Content Coal power plant 1.0 %P ± 0.5 %P Superheater/Reheater spray flow 2%of Main STM flow Not Applicable Fuel consumption, measuring 10 % N/A CO Content, measuring 150 ppm ± 50 ppm 16/42
Operation parameter Rating vs test average acceptable Test average acceptable deviation limit vs deviation limit instantaneous value acceptable deviation limit Main STM Pr Absolute Pr ±3 % Absolute Pr ±0.25 % or ±0.35 kg/ cm2 Large value Main STM & R/H STM Temp 1ry flow ±16 ( Degreeof superheat 30 over) ±8 (Degreeof superheat 15~30 ) ±4 (Degree of superheat 30 over) ±2 (Degree of superheat 15~30 ) Diff Pr ±1.0 % ( change cycle 2 times over vs writing cycle ) Not Specified Diff Pr ±4.0 % (Small case of change cycle ) R/H Pr drop ±50 % Not Specified Extraction Pr ±5 % Not Specified Final FW Temp ±6 Not Specified Exhaust Pr ±2.6 mmhg or Absolute Pr ±1.03 mmhg or Absolute Pr ±2.5 % large value ±1.0 % large value Power ±5 % ±0.25 % (1,250 KW for 500 MW) Voltage ±5 % Not Specified Power factor Not Specified ±1.0 % (0.01) Speed ±5 % ±0.25 % (9 rpm) 17/42
Input-Output Method ηp = Power output Fuel consumptio 860 n HHV 100 (%) Heat loss Method ηp= Efficiency Efficiency PlantLoss 18/42
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heat balance 21/42
Input-out put method ηb = Fuel consumptio n output HHV + Heat credits 100 (%) Heat loss method (ASME PTC 4.1, 1968) ηb = Total Heat loss [ 1 ] HHV + Heat credits 100 (%) Energy balance method (ASME PTC 4, 1998) ηb = Heat Loss - Heat credits [ 1 ] HHV 100 (%) 22/42
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heat loss 24/42
heat loss of fuel source D e s c r i p t i o n Symbol Unit Coal-1 Coal-2 Coal-3 Oil Gas Heat Losses Percentage Heat Loss of Dry Flue Gas LG(%) % 3.78 4.18 3.80 5.04 2.78 Heat Loss of H2O from Combustion LH(%) % 3.59 3.31 3.51 6.45 10.00 Heat Loss of Moisture in Fuel LMF(%) % 1.03 1.03 1.02 0.00 0.00 Heat Loss of Unburned Carbon LUC(%) % 1.00 0.59 0.40 0.00 0.00 Heat Loss of Moisture in Air LMA(%) % 0.07 0.07 0.06 0.09 0.10 Heat Loss of Atomizing Steam LAZ(%) % 0.00 0.00 0.00 0.02 0.00 Heat Loss of CO Formation LCO(%) % 0.00 0.00 0.00 0.00 0.00 Heat Loss of Latent Heat in Ash LP(%) % 0.00 0.00 0.00 0.00 0.00 Heat Loss of Radiation LB(%) % 0.19 0.18 0.19 0.18 0.20 Heat Loss of Unmeasured LUM(%) % 0.50 0.25 0.25 0.22 0.00 Total Heat Loss L(%) % 10.16 9.61 9.23 12.00 13.08 Thermal Efficiency, Designed YD % 89.84 90.39 90.77 88.00 86.92 25/42
check of detail chemical composition for efficiency relation to combustion calculation Heat loss calculation of performance testing Combustion air flow and flue gas flow calculation % Weight indication of C, H, O, N, S, Ash 6 ingredient ( Dry Base standard) O =100 - (C + H + N + S + Ash) calculation Using as fired fuel of efficiency calculation 26/42
Test method : Heat loss method (in-output method reference) Basis of air temp : Atmosphere temp (FD fan in air temp), 25 Calorie value of fuel : As fired higher heating value Ultimate analysis of fuel : Dry Base Moisture of fuel : Total moisture by proximate analysis Gas analysis : Air heater in & out O 2, CO 2, and CO Content Air & gas flow : Calculation by composition of fuel / flue gas Specific heat of fluid : Calculation by fuel/flue gas composition, temp & pr of liquid Moisture in air: Calculation by measured atmosphere pr, dry & wet temp Property of air & gas : Property of Dry Base 27/42
Atmosphere Pr : FDF Suction 1point Dry & wet temp : FDF Suction 1point Atmosphere temp : FDF Suction 2 point (PAF 2) Air heater in air temp : Multi-Point Air heater out air temp : Multi-Point Air heater in flue gas temp & gas composition : Multi-Point Air heater out flue gas temp & gas composition : : Multi-Point fluid Pr : Eco in/out, Drum, SH out, RH in/out, SH and RH Spray fluid temp : " fluid flow : basis flow, S/H, R/H spray flow 28/42
o Test result filing (organize measuring data) - Fuel analysis, combusting air temp - Ash analysis, flue gas analysis & temp - Moisture in air, etc. Dry flue gas flow calculation Combusting air flow calculation A/H air leakage ratio calculation Heat loss calculation Heat credits calculation efficiency calculation 29/42 efficiency correction
Test boundary 30/42
Test boundary 31/42
Test boundary 32/42
Test result filing Enthalpy calculation Unaccountable flow calculation o Flow calculation - Basis flow & 2 nd flow calculation - FW heater cycle heat balance - Main steam flow & R/H steam flow 33/42 Power output calculation Heat rate calculation o ELEP calculation - ELEP assumption - LP TBN Exhaust flow calculation - Condenser input heat calculation - UEEP calculation - Exhaust loss calculation - ELEP calculation TBN internal efficiency calculation Calculation result correction Test result analysis
Steam turbine heat balance Envelope Boundary Power Output Heat supplied Loss Main steam heat Reheat steam heat A/E steam heat Make-up water heat BLR Aux steam drain Heat returned Cold reheater steam heat FW heater out FW heat Superheater spray water heat BLR Aux steam heat TBN internal loss Stage loss/exhaust loss Pr drop of stage/mechanical loss External leak loss/radiant loss Condenser loss cycle loss Generator loss Electrical & Mechanical loss Heat rate = Heat supplied - Heat returned Power output 34/42 ( kj / kwh )
thermal efficiency (Heat rate or input-output method) ηt = output Input 100(%) = Electricpower 860* 100(%) Heatsupplied- Heat returned Output = kw = kj/s 3,600/4.1868 = 859.8452 kcal/h HR = (Heat supply - Heat return) / Electric power (kcal/kwh) Heat loss method ηt = efficiency - Pipe loss - Condenser loss Enthalpy drop efficiency method ηi = (hi (hi ho) hs) 100 (%) Calculation of each inlet-outlet HP,IP,LP by actual & adiabatic enthalpy 35/42
heat loss 36/42
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END THANK YOU VERY MUCH 42/42